AvE

10 Articles

Epsom Salts Restores Lead Acid Battery

January 20, 2019 by 21 Comments

Despite a lot of advances in battery technology, lead acid batteries are still used in many applications due to cost and their ability to provide a lot of surge current. But they don’t last forever. However, [AvE] shows that in some cases a failed battery can be restored with — of all things — epsom salts. If it makes you feel funny to use the stuff grandpa soaks in when he has a backache, you can call it magnesium sulfate.

You can find a complete explanation in the video below (which includes [AvE’s] very colorful language), but fundamentally, the magnesium sulfate dissolves lead sulfate build-up on the battery plates. The fix is usually temporary because this build-up occurs with other failure mechanisms like plate material shedding and collecting at the bottom of the battery. Obviously, epsom salt can’t repair damaged plates or do any other magic cure.

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Dissecting The Elusive Wax Motor

June 18, 2018 by 34 Comments

We’d wager most readers aren’t intimately acquainted with wax motors. In fact, a good deal of you have probably never heard of them, let alone used one in a project. Which isn’t exactly surprising, as they’re very niche and rarely used outside of HVAC systems and some appliances. But they’re fascinating devices, and once you’ve seen how they work, you might just figure out an application for one.

[AvE] recently did a complete teardown on a typical wax motor, going as far as cutting the thing in half to show the inner workings. Now we’ve seen some readers commenting that everyone’s favorite foul-mouthed destroyer of consumer goods has lost his edge, that his newer videos are more about goofing off than anything. Well we can’t necessarily defend his signature linguistic repertoire, but we can confidently say this video does an excellent job of explaining these little-known gadgets.

The short version is that a wax motor, which is really a linear actuator, operates on the principle that wax expands when it melts. If a solid block of wax is placed in a cylinder, it can push on a piston during the phase change from solid to liquid. As the liquid wax resists compression, the wax motor has an exceptionally high output force for such a small device. The downside is, the stroke length is usually rather short: for the one [AvE] demonstrates, it’s on the order of 2 mm.

By turning heat directly into mechanical energy, wax motors are often used to open valves and vents when they’ve reached a specific temperature. The common automotive engine thermostat is a classic example of a wax motor, and they’re commonly found inside of dishwashers as a way to open the soap dispenser at the proper time during the cycle.

This actually isn’t the first time we’ve featured an in-depth look at wax motors, but [AvE] actually cutting this one in half combined with the fact that the video doesn’t look like it was filmed on a 1980’s camera makes it worth revisiting the subject. Who is going to build a wax motor power device for the Power Harvesting Challenge in the 2018 Hackaday Prize?

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Blinging Up A Scope: Scale Your Divisions In Style

June 14, 2018 by 20 Comments

When a hacker owns an oscilloscope, it’s more than a possession. Weary nights are spent staring at the display, frantically twiddling the dials to coax out vital information. Over time, a bond is formed – and only the best will do for your scope. So why settle for the stock plastic dials when you could go for gold? Well in case you hadn’t noticed, we’re partial to a bit of over-engineering here at Hackaday, and [AvE] has upgraded his Rigol scope by adding metal knobs.

Employing his usual talent in the shop, [AvE] first turns the basic knob shapes from the stock, before drilling them and milling the outer texture pattern at an angle. Voilà: six custom knobs for 100% more torque and traction control. No matter how trivial the project, it’s always good to watch him at work. This [AvE] video doesn’t come with the usual fruity language warning; instead this build is set to the swelling tones of Beethoven. “Less Talk – More Action!” says the title, but we have to say that we miss his quips. That said, he still manages to deliver his signature humour through action alone.

For some slightly more functional oscilloscope upgrades, you can read about adding a hybrid touchscreen interface, or hacking a Rigol scope’s software to unlock greater bandwidth, storage depth and more.

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Cutting Stone With A Diamond Bit Built From Plumbing Parts

September 15, 2017 by 24 Comments

Everyone’s favorite Canadian is at it again. This time, [AVE] needed to cut a large hole in a stone countertop. They making coring bits for this, but a bit this size would cost upwards of $400. Not a problem. [AvE] broke out the tools and built his own stone cutting bit.

Everything starts with a 6″ plastic pipe cap. [AvE] center drilled the cap, then threaded it. A turned down bolt makes a great arbor for this new tool. The edge of the cap was then slotted. [AvE] used a clapped out Bridgeport milling machine, but you could do the same job with a hacksaw or a Dremel tool.

The secret sauce is industrial diamonds. That’s right, this is a diamond cutting bit. [AvE] ordered 20 grams of 20-25 mesh industrial diamonds. “Mesh” defines the size of the individual diamonds — in this case around 50 microns and up.  Now, how to bind diamond and plastic? Plumber’s transition cement didn’t work – the diamonds and coating just peeled off like a sunburn. The solution turned out to be JB-Weld. A liberal coating of JB-Weld on the face of the tool, a sprinkling of industrial diamonds, and the pipe cap was ready to cut.

The cutting operation was slow, steady, and lots of cooling water. [AvE] made it most of the way through his countertop before having to refurbish his bit.

[AvE] usually is a man of many words, as can be seen in this post about his EDM machine. This time though, he gave us the silent treatment — an entire video with no words, set to classical music. It’s great seeing YouTubers step outside their comfort zone and trying something new.

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Drill Press To Mill Conversion

July 4, 2017 by 39 Comments

Every time we look at the little short Z axis of our CNC mill, we think about converting a drill press to a mill. In theory, it seems like it ought to be easy, but we never quite get around to it. [AvE] did get around to it and made his usual entertaining video about it that you can see below. If you haven’t seen any of [AvE’s] videos before, be warned: there is a little colorful language in a spot or two.

This isn’t a CNC mill, by the way, although we suspect you could convert it. Essentially, he adds a spindle and an XY table to a Ryobi drill press. It sounds simple, but getting everything to work did take a few tricks, including a blow torch.

Actually, turns out the blow torch didn’t really do it, but we won’t spoil the final resolution to the problem. Once it was resolved, though, he did manage to do some actual milling, accompanied by some music we wouldn’t associate with [AvE].

Although billed as a “poor man’s” build, the XY table alone was about $200. So add in the cost of the drill press, the spindle, and the mill and this is still a fair chunk of cash. We’d love to see it compared to a Harbor Freight milling vise. We suspect the Harbor Freight vise might not be as good, but is the difference worth the $130 difference in price?

We’ve seen this kind of conversion done before without the colorful language. If you do this conversion and want some practice, why not build a magnetic carabiner?

Amazing Carbon Foam Doesn’t Take Much Bread

August 27, 2016 by 28 Comments

A lot of people knew the Space Shuttle had ceramic tiles to protect its nose from reentry heat. That’s mostly because the tiles fell off a lot and each one was a unique shape, so it got a lot of press coverage. However, you didn’t hear as much about the parts of the orbiter that got really hot: the forward part of the wings and the tip of the nose. For those, NASA used an exotic material called RCC or reinforced carbon-carbon. Other uses include missile nose cones and Formula One brakes. A similar material, carbon fiber-reinforced silicon carbide appears in some high-end car brakes. These materials can take high temperatures, easily.

[AvE] wanted to make some carbon foam for experiments. It does take a little bread, though. Not money, but literal bread. To create the foam, he burns bread slices in a chamber full of argon. The stuff has some amazing properties.

In the video below, you can see the foam protecting a thermocouple from a torch flame and even holding melting aluminum. Not bad for a few pieces of bread.

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Hackaday Links: It’s Mother’s Day And You Forgot

May 8, 2016 by 8 Comments

[AvE] noticed someone was having trouble with their Nepeploid Shilden Inversker, and after a sinusoidal lambda deplanarization test, noticed the dinglebop wouldn’t pass through the grumbo. [AvE] is probably just some guy who wears overalls to bed, but he does know a polyfractal magnetorestrictor when he sees one. To wit, he has a novel application of Eularian magnetronics resulting in a friction factor over unity. Game changing stuff here, from the guy who brought you the beer stein made out of an oil filter.

It was soft launched at the Midwest RepRap Festival this year, and now Lulzbot’s TAZ 6 is finally out. The biggest new feature? The electronics ‘brain box’ holds everything, including the power supply. This tower of brain box makes the Taz 6 harder to build from source, but there are unconfirmed reports that Lulzbot may sell this brainbox separately.

Boldport, and founder [Saar Drimer] are the cream of the crop when it comes to artistic PCBs. Boldport’s catalog and [Saar]’s portfolio include a tribute to [Bob Pease], a beautiful board with multicolor solder masks, and an emergency business card. Now Boldport is doing a beautiful PCB of the month club. It’s called Boldport Club, and each three-month membership gets you three months of pretty PCBs. The shop will also stop taking orders for the Boldport club 25 hours after this post goes live. If you missed the boat on the club, you can still get in on the pretty PCB action – we have the Boldport cordwood puzzle available in the Hackaday store.

The Apple IIgs was the last gasp of the Apple II before that platform was phased out for the Macintosh. Despite being mostly forgotten, except for thousands of units in middle school computer labs until the 2000s, it was a very interesting machine, with a wavetable synth, real multitasking, a GUI, and very high resolution graphics. After 30-odd years the IIgs now has quadraphonic sound. The 4soniq card was introduced at the WOzFest III conference last month, and it will give an Apple IIgs with four channels of audio output.

There’s a lot of stuff happening next weekend, and Hackaday is going to be there. If you’re at the Maker Faire Bay Area, Hackaday is taking over a pub. It’s on Saturday night, so it doesn’t conflict with the bring-a-hack at an undisclosed location on Sunday night. Me? I’m going to hamvention, mostly for the purposes of documenting the two parking lots full of swap meet. Find me and I’ll get you some Hackaday swag.